Support bracket for casing of a condensing unit

ABSTRACT

A support bracket suitable for use in a casing of an outdoor condensing unit includes a main body configured to reside between a corner post and a coil of the condensing unit, a first extension member extending from a first end of the main body, and a second extension member extending from a second end of the main body. The first extension member is configured to attach to a first inlet grille of the condensing unit. The second extension member is configured to attach to a second inlet grille of the condensing unit.

BACKGROUND OF THE INVENTION

The present invention relates generally to a support. More particularly, the present invention relates to a support bracket configured to support a protective casing for a condenser coil.

A split system heating and/or cooling system includes an outdoor unit, such as a condensing unit, and an indoor unit, such as an evaporator unit. The condensing unit typically includes a condenser coil, inlet grilles for protecting the coil, a top cover, and a base pan for containing the condensing unit and receiving condensation that drips from the coil.

Commonly, the condensing unit includes an inlet grille on each of the four sides of the condensing unit. A corner post may be used at the corners of the condensing unit to secure each end of the inlet grilles.

BRIEF SUMMARY OF THE INVENTION

The present invention relates to a support bracket suitable for use in a casing of an outdoor condensing unit. The support bracket includes a main body configured to reside between a corner post and a coil of the condensing unit, a first extension member extending from a first end of the main body, and a second extension member extending from a second end of the main body. The first extension member is configured to attach to a first inlet grille of the condensing unit. The second extension member is configured to attach to a second inlet grille of the condensing unit.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an outdoor condensing unit.

FIG. 2A is a perspective view of an embodiment of a support bracket.

FIG. 2B is a top view of the support bracket of FIG. 2A.

FIG. 2C is a cross-sectional view of a portion of the support bracket of FIG. 2B.

FIG. 2D is a cross-sectional view of another portion of the support bracket of FIG. 2B.

FIG. 3 is a perspective view of a portion of the outdoor condensing unit of FIG. 1 with a top cover of the unit removed.

DETAILED DESCRIPTION

FIG. 1 is a perspective view of outdoor condensing unit 10 of an air conditioning or heat pump system. Condensing unit 10 includes fan 12, coil assembly 14 (not shown in FIG. 1; see FIG. 3), top cover 16, first inlet grille 18, second inlet grille 20, base pan 22, first corner post 24, control box 26, and second corner post 28.

First inlet grille 18 and second inlet grille 20 are configured for protecting coil assembly 14, which includes copper tubing and thin aluminum fins that are used to form a coil. Condensing unit 10 includes two additional inlet grilles, which are not visible in FIG. 1. A third inlet grille is located on an opposing side of first inlet grille 18, and a fourth inlet grille is located on an opposing side of second inlet grille 20.

First corner post 24 resides between first and second inlet grilles 18 and 20, and also protects coil assembly 14. Corner post 24 may be attached to top cover 16 and to base pan 14. First and second inlet grilles 18 and 20 may also be attached to top cover 16 and to base pan 14. A portion of second corner post 28 is also visible in FIG. 1 and resides between first inlet grille 18 and the fourth inlet grille. A third corner post (not visible in FIG. 1) is located opposite to first corner post 24 and resides between the third and fourth inlet grilles. The corner posts and inlet grilles of unit 10 form a protective casing around coil assembly 14. Top cover 16 also may be part of the protective casing of condensing unit 10.

Although the discussion below is in reference to first inlet grille 18, second inlet grille 20, and first corner post 24, this discussion also applies to the other inlet grilles and corner posts of condensing unit 10.

During manufacturing and assembly of condensing unit 10, top cover 16 may be attached to unit 10. Top cover 16 may be assembled onto unit 10 during the final or near final steps of the manufacturing and assembly process. Top cover 16 may serve as a support for inlet grilles 18 and 20 near a top portion of coil assembly 14. Thus, inlet grilles 18 and 20 may not be supported near a top portion of coil assembly 14 until top cover 16 is attached to unit 10. As a result of this lack of support, inlet grilles 18 and 20 may bow away from coil assembly 14 during assembly of condensing unit 10. If inlet grilles 18 and 20 bend beyond a certain point, the structural integrity of the grilles may be comprised, which may lead to failure or breakage.

In order to attach top cover 16 to corner post 24, an aperture in a center of a top portion of corner post 24 may be used to receive a fastener that first passes through top cover 16. If only one fastener is used to fix top cover 16 to corner post 24, corner post 24 may not be adequately secured to top cover 16, in terms of preventing movement of corner post 24. As such, the sides of corner post 24 may be able to bend around a center of corner post 24 and rattle against top cover 16.

Inlet grilles 18 and 20 and corner post 24 are configured as a cage or casing around coil assembly 14 to protect the coil. However, in designs as described above, in which a fastener is used to fix top cover 16 to corner post 24, an end of the fastener may likely puncture the coil during shipping or assembly.

The present invention relates to a support bracket suitable for use in outdoor condensing unit 10 in order to provide support to inlet grilles 18 and 20 and corner post 24, as well as protect coil assembly 14. The support bracket is configured to eliminate the potential for the problems mentioned above.

FIG. 2A is a perspective view of a preferred embodiment of a support bracket in accordance with the present invention. As shown in FIG. 2A, support bracket 30 includes main body portion 32, first tab member 34 a, second tab member 34 b, first extension member 36 a, and second extension member 36 b. First extension member 36 a includes first corner portion 38 a, first fastener portion 40 a, and first end portion 42 a. Similarly, second extension member 36 b includes second corner portion 38 b, second fastener portion 40 b, and second end portion 42 b.

As described in more detail below, support bracket 30 is configured to be located between corner post 24 and coil assembly 14 of FIG. 1 to support corner post 24 and protect the coil. In addition, first extension member 36 a and second extension member 36 b are configured to support inlet grilles 18 and 20 of FIG. 1.

Main body portion 32 of support bracket 30 is configured to be located behind corner post 24. Main body portion 32 includes rib 44, which provides rigidity to main body portion 32.

First tab member 34 a and second tab member 34 b are each configured to engage with corner post 24, as described in further detail below with reference to FIGS. 2B and 2C. First corner portion 38 a and second corner portion 38 b are each configured to engage with a flange on corner post 24, as discussed below in reference to FIG. 3. First fastener portion 40 a, having aperture 46 a, is configured to engage with first inlet grille 18 and top cover 16; similarly, second fastener portion 40 b, having aperture 46 b, is configured to engage with second inlet grille 20 and top cover 16. First and second end portions 42 a and 42 b are configured to press against the coil of coil assembly 14.

FIG. 2B is a top view of support bracket 30 of FIG. 2A, which includes main body portion 32 having rib 44, first tab member 34 a, second tab member 34 b, first extension member 36 a, and second extension member 36 b.

As shown in FIG. 2B, main body portion 32 has a length L1 and rib 44 has a length L2. In the embodiment of bracket 30 in FIGS. 2A-2D, length L2 of rib 44 is approximately 65 percent of length L1 of main body portion 32. It is recognized that rib 44 may be various lengths, and in other embodiments, length L1 may be smaller or greater than as shown in FIG. 2A.

First extension member 36 a includes first corner portion 38 a, which has long portion 48 a extending from an end of tab member 34 a and short portion 50 a that connects with fastener portion 40 a. Long portion 48 a and short portion 50 a are oriented approximately 90 degrees relative to one another such that a flange on corner post 24 is configured to rest against short portion 50 a. Similarly, second extension member 36 b includes second corner portion 38 b having long portion 48 b extending from an end of second tab member 34 b and short portion 50 b connecting to second fastener portion 40 b. A second flange located on an opposite side of corner post 24 is configured to rest against short portion 50 b of second corner portion 38 b. As shown in FIG. 3 below, first and second corner portions 38 a and 38 b are configured to facilitate an interference fit between corner post 24 and support bracket 30.

FIG. 2C is a cross-sectional view of first tab member 34 a of FIG. 2B. Tab member 34 a includes front portion 52 a and back portion 54 a having dimple 56 a. Tab member 34 a is configured to engage with corner post 24 such that front portion 52 a may be inserted over corner post 24 to secure bracket 30 to corner post 24, and back portion 54 a resides behind corner post 24. Dimple 56 a of tab member 34 a is configured to align with a hole on corner post 24. Tab member 34 b similarly has a dimple configured to align with another hole on corner post 24.

FIG. 2D is a cross-sectional view of main body portion 32 including rib 44. As described above, rib 44 is used to provide rigidity and additional structural support to main body portion 32 such that main body portion 32 is not able to flex. Rib 44 is configured to rest against a back side of corner post 24. As shown in FIG. 2D, main body portion 32 has a width W1 and rib 44 has a width W2. In the embodiment of bracket 30 shown in FIGS. 2A-2D, width W2 is approximately a third of width W1; however, it is recognized that width W2 may be smaller or larger in other embodiments.

Support bracket 30 is configured such that main body portion 32 is rigid, while first and second extension members 36 a and 36 b are flexible. Support bracket 30 may be formed from any metal or any other suitable material. In a preferred embodiment, support bracket 30 may formed from a sheet metal made of steel. Support bracket 30 may be formed by various known stamping techniques, including, but not limited to, using a progressive die.

FIG. 3 is a perspective view of a portion of condensing unit 10 of FIG. 1, with top cover 16 removed from condensing unit 10. FIG. 3 shows coil assembly 14, first inlet grille 18, corner post 24, second inlet grille 20, and support bracket 30 of FIGS. 2A-2D. Although support bracket 30 is shown in FIG. 3 between first and second inlet grilles 18 and 20 and behind corner post 24, it is recognized that support bracket 30 may also be used to support second corner post 28 and the third corner post, and the corresponding inlet grilles. As such, condensing unit 10 of FIG. 1 may include three support brackets.

Corner post 24 includes aperture 60, which is located in a center of corner post 24 and is configured for receiving a fastener that attaches top cover 16 (not shown) to corner post 24. Because main body portion 32 of support bracket 30 is located behind corner post 24, support bracket 30 protects coil assembly 14 from being punctured by the fastener received through corner post 24.

As shown in FIG. 3, front portion 52 a of first tab member 34 a is hooked over corner post 24; similarly, front portion 52 b of second tab member 34 b is hooked over corner post 24 at an opposite end of corner post 24. Although not visible in FIG. 3, back portion 54 a of first tab member 34 a is located behind corner post 24, and dimple 56 a aligns with a hole in corner post 24; similarly, back portion 54 b of second tab member 34 b is located behind corner post 24, and a dimple on second tab member 34 b aligns with a hole on an opposite end of corner post 24.

As shown in FIG. 3, first inlet grille 18 includes post 62 having aperture 64. Support bracket 30 is configured such that aperture 46 a of first fastener portion 40 a is aligned with aperture 64 of post 62. In order to attach top cover 16 to inlet grille 18, a fastener is inserted through top cover 16 and then through aperture 46 a and aperture 64. Similarly, second inlet grille 20 includes post 66 having aperture 68. Aperture 46 b of second fastener portion 40 b is aligned with aperture 68 of post 68 to attach top cover 16 to inlet grille 20.

Support bracket 30 provides further support to corner post 24 by way of first corner portion 38 a and second corner portion 38 b. As explained above in reference to FIG. 2B, first corner portion 38 a includes long portion 48 a and short portion 50 a, which are configured such that there is an interference fit between first flange 70 of corner post 24 and first corner portion 38 a. Similarly, an interference fit exists between second flange 72, located on an opposite side of corner post 24, and second corner portion 38 b. Support bracket 30 is configured such that first end portion 42 a and second end portion 42 b each press against coil assembly 14, as shown in FIG. 3.

To assemble a condensing unit similar to condensing unit 10 of FIGS. 1 and 3, which includes support bracket 30, a first step is to attach a compressor to base pan 22 and then set coil assembly 14 into base pan 22. Next, a bottom portion of first inlet grille 18 may be attached to base pan 22 with fasteners, such as screws. Bracket 30 may then be attached to corner post 24 by hooking first and second tab members 34 a and 34 b onto corner post 24. Next, a bottom portion of corner post 24 may be attached to base pan 22, and fastener portion 40 a of bracket 30 is aligned with post 62 of inlet grille 18 such that bracket 30 is resting over inlet grille 18. Second inlet grille 20 may then be attached by first fastening a bottom portion of second inlet grille 20 to base pan 22. Post 66 of second inlet grille 20 may then be placed behind support bracket 30 such that aperture 46 b of fastener portion 40 b is aligned with aperture 68 of post 66.

These steps, attaching a grill, then a corner post, then a second grill, are repeated until condensing unit 10 includes four inlet grilles, three corner posts, and a control box. In reality, assembly of unit 10 may likely begin with one of the inlet grilles that are not visible in FIG. 1. As such, first inlet grille 18 may actually be the third inlet grille to be assembled onto unit 10. Similarly, corner post 24 may be the third and final corner post assembled onto unit 10.

Finally, top cover 16 is placed on unit 10 and fasteners are used to secure top cover 16 at various positions around unit 10. As explained above, a fastener is received through top cover 16 and aperture 60 of corner post 24 to attach top cover 16 and corner post 24. In addition, a second fastener is received through top cover 16, aperture 46 a of support bracket 30, and aperture 64 of first inlet grille 18. A third fastener is received through top cover 16, aperture 46 b of support bracket 30, and aperture 68 of second inlet grille 20.

It is recognized that various methods may be used to assemble condensing unit 10, in addition to or as an alternative to the steps outlined above.

The terminology used herein is for the purpose of description, not limitation. Specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as bases for teaching one skilled in the art to variously employ the present invention. Although the present invention has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention. 

1. A support bracket suitable for use in a casing of an outdoor condensing unit, the support bracket comprising: a main body configured to reside between a corner post and a coil of the condensing unit; a first extension member extending from a first end of the main body; and a second extension member extending from a second end of the main body, wherein the first extension member is configured to engage with a first inlet grille of the condensing unit and the second extension member is configured to engage with a second inlet grille of the condensing unit.
 2. The support bracket of claim 1, wherein the main body comprises a first tab member and a second tab member that are each configured to engage with the corner post.
 3. The support bracket of claim 2, wherein the first and the second tab members each include a dimple configured to align with a first hole and a second hole of the corner post.
 4. The support bracket of claim 1, wherein the first extension member includes an aperture for receiving a fastener through the first extension member to attach the first extension member to a post of the first inlet grille.
 5. The support bracket of claim 1, wherein the main body comprises a rib member configured to provide rigidity to the main body.
 6. The support bracket of claim 1, wherein the first extension member further comprises a first end portion extending from an end of the first extension member opposite to the main body and configured to contact the coil of the condensing unit.
 7. The support bracket of claim 1, wherein the support bracket is formed from sheet metal.
 8. A protective casing for a condenser coil, the protective casing comprising: a first inlet grille; a second inlet grille; a corner post positioned between the first and second inlet grilles; and a support bracket comprising: a main body positioned between the corner post and the condenser coil; and a first extension member and a second extension member extending from opposite ends of the main body and configured such that the first extension member is attachable to the first inlet grille and the second extension member is attachable to the second inlet grille.
 9. The protective casing of claim 8, wherein the first extension member includes an aperture and the first inlet grille includes a top post, and a fastener is received through the aperture of the first extension member and engaged with the top post to attach the support bracket to the first inlet grille.
 10. The protective casing of claim 8, wherein the main body of the support bracket includes a pair of tab members configured to engage with the corner post.
 11. The protective casing of claim 10, wherein the tab members hook onto the corner post to secure the support bracket to the corner post.
 12. The protective casing of claim 8 further comprising a top cover configured to attach to the corner post and to the support bracket.
 13. The protective casing of claim 12, wherein the top cover is configured to attach to the corner post at a first attachment point, to the first inlet grille and the first extension member at a second attachment point, and to the second inlet grille and the second extension member at a third attachment point.
 14. The protective casing of claim 8, wherein the first extension member includes a corner portion configured to engage with a first flange on the corner post, and the second extension member includes a corner portion configured to engage with a second flange on the corner post.
 15. A method of protecting a coil assembly for a condensing unit, the method comprising: securing an inlet grille around an outside of the coil assembly; securing a corner post around an outside corner portion of the coil assembly; and supporting the inlet grille at a top portion of the inlet grille such that the inlet grille is essentially immobile; and supporting the corner post such that the corner post is essentially immobile.
 16. The method of claim 15, wherein a support bracket is used to support the inlet grille at the top portion of the inlet grille.
 17. The method of claim 16, wherein a fastener is received through an aperture in the support bracket and engaged with a hole in the inlet grille.
 18. The method of claim 15, wherein a support bracket is used to support the corner post and a portion of the support bracket attaches to the corner post.
 19. The method of claim 15 further comprising: positioning a top cover over the coil assembly; securing the top cover to the inlet grille; and securing the top cover to the corner post.
 20. The method of claim 19, wherein securing the top cover to the inlet grille includes positioning a support bracket between the top cover and the inlet grille.
 21. The method of claim 19 further comprising: shielding the coil assembly from being punctured by a fastener used to secure the top cover to the corner post.
 22. The method of claim 21, wherein a support bracket positioned between the corner post and the coil assembly is used to shield the coil assembly. 